Graphenix Development, Inc.

Kevin Tanzil

John C Brewer

Paul D Garman

Robert G Anstey

Isaac Lund

Bernard Philip Gridley

Kyle P Povlock

Peter Symons

Richard Allen Castle

John M Pochan

Alexander J Warren

William P McKenna

Isaac N Lund

An anode for an energy storage device includes a current collector having an electrically conductive layer that includes nickel or copper, and a lithium storage structure comprising a plurality of first microstructures in contact with the electrically conductive layer. Each first microstructure includes silicon and is characterized by a first maximum width measured across the widest section orthogonal to the first microstructure axis. Each first microstructure includes a first portion characterized by the width substantially tapering from the maximum width to a location where each first microstructure contacts the electrically conductive layer and a second portion positioned farther from the electrically conductive layer than the first portion, the second portion defining a substantially hemispherical shape and the top of each first microstructure. The lithium storage structure has at least 1 mg/cmof active silicon and a total atomic % of nickel and copper is from 0.5% to 1.2%.

Anodes for lithium-based energy storage devices

An anode for an energy storage device includes a current collector having an electrically conductive layer and a surface layer overlaying the electrically conductive layer. A lithium storage layer may overlay the surface layer. The surface layer may include manganese. The lithium storage layer may include at least 40 atomic % silicon, germanium, or a combination thereof.

An anode for an energy storage device may include a current collector. An anode may include a first lithium storage layer overlaying the current collector. An anode may include a first intermediate layer overlaying at least a portion of the first lithium storage layer. An anode may include a second lithium storage layer overlaying the first intermediate layer. The first lithium storage layer may be a continuous porous lithium storage layer including a total content of silicon, germanium, or a combination thereof, of at least 40 atomic %. The first intermediate layer may include a first sublayer in contact with an underlying lithium storage layer and a second sublayer overlaying the first sublayer and in contact with an overlying lithium storage layer, the first sublayer having different a chemical composition than the second sublayer.

Multilayer anodes for lithium-based energy storage devices

An anode for a lithium-based energy storage device such as a lithium-ion battery is disclosed. The anode includes an electrically conductive current collector comprising an electrically conductive layer and a transition metal oxide layer overlaying the electrically conductive layer. The anode may include a continuous porous lithium storage layer provided over the transition metal oxide layer. The continuous porous lithium storage layer may include at least 80 atomic % silicon. A method of making the anode may include providing an electrically conductive current collector having an electrically conductive layer and a transition metal oxide layer provided over the electrically conductive layer. A continuous porous lithium storage layer is deposited over the transition metal oxide layer by PECVD. The continuous porous lithium storage layer has a total content of silicon of at least 80 atomic %.

An anode for a lithium-based energy storage device such as a lithium-ion battery is disclosed. The anode includes an electrically conductive current collector comprising an electrically conductive layer and a transition metal oxide layer overlaying the electrically conductive layer. The anode may include a continuous porous lithium storage layer provided over the transition metal oxide layer. The continuous porous lithium storage layer may include at least 80 atomic % amorphous silicon and a silicide-forming metallic element in a range of 0.1 to 10 atomic %. A method of making the anode may include providing an electrically conductive current collector having an electrically conductive layer and a transition metal oxide layer provided over the electrically conductive layer. The transition metal oxide layer may have an average thickness of at least 0.05 μm. A continuous porous lithium storage layer is deposited over the transition metal oxide layer by PECVD.

An anode for an energy storage device is provided that includes a current collector having an electrically conductive layer, a plurality of lithium storage filamentary structures in contact with the electrically conductive layer. For each lithium storage filamentary structure of the plurality of lithium storage filamentary structures, there is a first supplemental layer overlaying at least a portion of the respective filamentary structure, the first supplemental layer including silicon nitride or a first metal compound. There is further a second supplemental layer overlaying at least a portion of the first supplemental layer, the second supplemental layer having a composition different from the first supplemental layer and comprising silicon nitride or a second metal compound.

Anode structures having a multiple supplemental layers

An anode for an energy storage device includes a current collector having a metal oxide layer. A continuous porous lithium storage layer overlays the metal oxide layer, and a first supplemental layer overlays the continuous porous lithium storage layer. The continuous porous lithium storage layer may be substantially free of nanostructures. The continuous lithium storage layer may include amorphous silicon deposited by a PECVD process. The first supplemental layer includes silicon nitride, silicon dioxide, or silicon oxynitride. The anode may further include a second supplemental layer overlaying the first supplemental layer.

Anodes for lithium-based energy storage devices, and methods for making same

A prelithiated anode may include a current collector may include a metal oxide layer. Prelithiated anodes may in addition include a lithiated storage layer overlaying the metal oxide layer. The lithiated storage layer may be formed by incorporating lithium into a continuous porous lithium storage layer may include at least 80 atomic % silicon. The lithiated storage layer may include less than 1% by weight of carbon-based binders. The lithiated storage layer may further include lithium in a range of 1% to 90% of a theoretical lithium storage capacity of the continuous porous lithium storage layer. Batteries may include the prelithiated anode.

Methods of making an anode for a lithium-based energy storage device such as a lithium-ion battery are disclosed. Methods may include providing a current collector. The current collector may include an electrically conductive layer and a surface layer overlaying over the electrically conductive layer. The surface layer may have an average thickness of at least 0.002 μm. The surface layer may include a metal chalcogenide including at least one of sulfur or selenium. Methods may include depositing a continuous porous lithium storage layer onto the surface layer by a PECVD process. The continuous porous lithium storage layer may have an average thickness in a range of 4 μm to 30 μm and comprises at least 85 atomic % amorphous silicon.

A method of making an anode for an energy storage device such as a lithium-ion energy storage device is disclosed. The method may include depositing a first lithium storage layer over a current collector by a first CVD process. The current collector may include a metal oxide layer, and the first lithium storage layer is deposited onto the metal oxide layer. The method may also include forming a first intermediate layer over at least a portion of the first lithium storage layer. The method may further include depositing a second lithium storage layer over the first intermediate layer by a second CVD process. At least the first lithium storage layer may be a continuous porous lithium storage layer having a total content of silicon, germanium, or a combination thereof, of at least 40 atomic %.

An anode for an energy storage device may include a current collector. The current collector may include a metal oxide layer. The metal oxide layer may include a doped oxide or zinc oxide. In addition, the anode may include a continuous porous lithium storage layer overlaying the metal oxide layer. The continuous porous lithium storage layer may include a total content of silicon, germanium, or a combination thereof, of at least 40 atomic %.

An anode for an energy storage device includes a current collector having a metal oxide layer. A continuous porous lithium storage layer overlays the metal oxide layer, and a first supplemental layer overlays the continuous porous lithium storage layer. The first supplemental layer includes silicon nitride, silicon dioxide, or silicon oxynitride. The anode may further include a second supplemental layer overlaying the first supplemental layer. The second supplemental layer has a composition different from the first supplemental layer and may include silicon dioxide, silicon nitride, silicon oxynitride, or a metal compound.

An anode for a lithium-based energy storage device such as a lithium-ion battery is disclosed. The anode includes an electrically conductive current collector comprising an electrically conductive layer and a transition metal oxide layer overlaying the electrically conductive layer. The anode may include a continuous porous lithium storage layer provided over the transition metal oxide layer. The continuous porous lithium storage layer may include at least 40 atomic % silicon. A method of making the anode may include providing an electrically conductive current collector having an electrically conductive layer and a transition metal oxide layer provided over the electrically conductive layer. The transition metal oxide layer may have an average thickness of at least 0.05 &#x3bc;m. A continuous porous lithium storage layer is deposited over the transition metal oxide layer by PECVD.

A method of making a prelithiated anode for use in a lithium-ion battery includes providing a current collector having an electrically conductive layer and a metal oxide layer overlaying the electrically conductive layer. The metal oxide layer has an average thickness of at least 0.01 &#x3bc;m. A continuous porous lithium storage layer is deposited onto the metal oxide layer by a CVD process. Lithium is incorporated into the continuous porous lithium storage layer to form a lithiated storage layer prior to a first electrochemical cycle when the anode is assembled into the battery. The anode may be incorporated into a lithium ion battery along with a cathode. The cathode may include sulfur or selenium and the anode may be prelithiated.

An anode for an energy storage device such as a lithium-ion energy storage device is disclosed. The anode includes a current collector having a metal oxide layer, a first lithium storage layer overlaying the current collector, a first intermediate layer overlaying at least a portion of the first lithium storage layer, and a second lithium storage layer overlaying the first intermediate layer. The first lithium storage layer is a continuous porous lithium storage layer having a total content of silicon, germanium, or a combination thereof, of at least 40 atomic %.

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Rochester, NY, United States of America

Kevin Tanzil